Power distribution system



Feb. 20, 1951 D. A. ENSIGN POWER DISTRIBUTION SYSTEM Filed Dec.

5 Sheets-Sheet 1 ATTORNEYS QARWHN .ENS8GN Feb. 20, 1951 D ENSIGN2,542,404

POWER DISTRIBUTION SYSTEM Filed Dec. 16, 1948 5 Sheets-Sheet 2 FIG. 3

gPVJQ/Tl w DARWlN A. ENSEGN,

ATTO R N EYE Feb. 20,195] E N 2,542,404

POWER DISTRIBUTION SYSTEM Filed Dec. 16, 1948 5 Sheets-Sheet 3 FIG. 4

DARWIN- A, ENSIGN,

$3, at, 4 4 W 4 ATTORNEYS Feb. 20, 1951 ENSIGN 2,542,404

POWER DISTRIBUTION SYSTEM Filed Dec. 16, 1948 5 Sheets-ShegI-A I N VENTOR.

63 DARWIN A. ENSIGN, 5 2 BY X 3 7 Attorneys D. A. ENSIGN POWERDISTRIBUTION SYSTEM Feb. 20, 1951 Filed Dec. 16, 194B FIG. l5

FIG. l6

Inventor:

DARWIN A. ENSIGN By 6&1, Wa% I Attorneys Patented Feb. 20, 19 51 POWER."DISTRIBUTION "SYSTEM Darwim'A. EnsigmlHuntington, Va., :assignor "to;Ensign Electric and Manufacturing Com- ;pany, Huntington, W. Va.-, acorporation .of West vVirginia [TED TATE'S PATENT or Fl CE .10' Claims.

This invention: relates to electric power .distributiomsystems, andmoreparticularly to:safety isystems .suchas are employed in .coal mines,

.andqthe'like. :While .the;;invention designed especia ly vfor .usein.such saietysystemsit is app icable toany situation vwhere. .sseparableconnectors are em- .ployed. .and where itlisrdesired .to prevent arcingor sparking .atthe. contacts. when .the members of .the connectorsare-separated.

.' I.'he, general.objeot of the invention is .to pro-.-

vide improved means, operated by the initial separating umovement.of....the .members tofz. a: connector. .for opening thezcircuit .atanother point and .thus :disconnecting the connector from the source ofcurrent .beforeathe'contaet "elements thereof ,aredisengaged, :wherebysuch contact elementsvare .dead, when. finallyseparated. .Al-

so to .provideuimproved-means f or preventing the circuit-from being.reeestablished until after the contact elementshave been .brought.tqgetherin. full engagement.

...More. specifically, .an..obj.ect. of .theinventionis to provide, inconnection .with the usual over.-

load. circuit breaker commonly interposed-in.

such lcircuits, improved .1means, operated by the initial separatinumovement. of the members of a connector, for. tripping .such .circuitbreaker...

and also improved .zmeans v.forpreventing-such breaker from,being..closed .againgheiore the'roontactelements. ottheiconnectorhavezbeen'bronght into (full eng gement, .aift'er having been separated.

Still .more .:specifically, .the invention ,contem plates the employmentof a circuit breaker con.- .structed with ;a.'shunt.trip..coil, and theprovision oi means operatedby the separating. movement ofilthe membersof a .connector .101: energizing suchooil.

.A .turther. object .of. the-invention .is: toiuprovide a..novelconstruction (if-connector equipped with animproved circuitclosercontrollingrthe circuit;- .breaker, and located wholly outsideof.-.the con-- nectorxhousinggor.casing.

.still another object.- is .to gprovidean.improvedconstruction ofconnector .in which. the wing member pivotally.mounted on, .thereceptaclemember and operates with .a .lever action, :.thus

.f acilitatingmoving the .contactelements into-and outofien agement.The:inventionaalsoconteme plates-the provision of .a mechanical .latchfor locking the pivotally connected members tQgethr er. when assembled.

1 with tthe above .androther robjectsiinaviewandimnrovegenerallyionz.therdetails cit-such. an

. =2 paratus, the invention consists of the construe.- tion andcombination of partshereinafter described and claimed, and illustratedin .the .accompanying drawings-forming partof this specification, and inwhich:

.Fig. l isaside elevationof my improvedcomnector complete as it appearswhen installed on,

a'suitable support such as a distribution.box,.a.

fragment of the latter being shown in section;

Fig. 2 is atransverse section .on .the line.2--2.

of Fig. 1.1ooking in the direction ofthearrows;

Fig. 3 is an :end elevation .of .the apparatus.

looking .atthe left hand-end .ofr-Fig. 1.;

Fig. 4, is a :longitudinal section through the (811- tireapparatus shownin Fig. Lsuchsection being taken substantially .on .the line 4-4 of.Fig. .3, looking in the directionof the. arrows;

Fig. .5 is a transverse sectionsubstantially on.

the line 5-5 of .Fig. 1,,:looking in thedirectionof the arrows;

Fig.6 is a face view-of the inner ends-of both membersof the connector,thesemembers beingshown in .a position .displacedl8.0 .from the .posi-'tion .shown inFigs. 1 and .41.;

Fig. 7 is .a fragmentary side elevation of my improved mercury .tubeswitch, looking fromrthe. side opposite that shown in Figs. 1 and .4;

Fig. 8 is a fragmentary side elevationcshowing,

a modified construction of circuit closing .or-oontrolling device;

Fig. 9.is an endelevationsimilar to Fig.3.hut showing only the lowerhalfof the .apparatusand illustrating another modified arrangement of.

. Fig. 16 is afragmentaryside ielevationwoman enlarged scaleshowingparts of the mechanism.

illustrated in Fig. .15.

Referring 'to the. drawings in detail, and ;more particularly ,firsttoFigs.;1.and .4 thereoi; my..'im.- proved connector comprises areceptacle or socket member I andaplug member gz eachrof 3 these membershaving a housing or casing enclosing the mechanism.

Although a plug and receptacle of the construction shown and describedherein can be used as a line connector, I have illustrated in thedrawings the connector having th receptacle member I supported on thewall X of a distribution box or other suitable structure. In some cases,this wall is provided with an opening, as shown, through which thecasing of the receptacle extends and this casing is provided with atransversely projecting flange 3 which fits against the wall X and maybe secured thereto as by means of screws. In other cases, the receptaclehousing may be formed integral with the cast metal wall of the box.

The plug member 2 consists of a portion of substantially rectangularcross-section made up of two sections 4 and 5 united by a flangedconnection 1, and a taperin pyramidal end portion 6 projecting axiallyfrom the section 5, the portions t, 5 and 6 thus constituting a plugmember of elongated form.

The casing of the plug member is pivotally mounted on the receptaclemember by means of Y a pivot pin ID extending through hinge member 3 onthe receptacle. The cooperating hinge member 8 on the plug is ofsemi-cylindrical shape, open on one side, as clearly shown in Fig. 4, sothat when the plug is swung from full line to dotted line position, thehinge member 8 may be completely disengaged from the pin Ill and theplug disconnected from the receptacle.

When in the closed or assembled position shown in Figs. 1 and 4 the plugand receptacle members are locked together by means of a latch I Imounted on a pivot 12 on the lower side of the receptacle member I,diametrically opposite the pivot 10. This latch is provided with asuitable spring l3 tending to maintain the latch in engagement with akeeper [4 carried at the lower side of the plug member. This latch, forlocking the members of the connector in assembled relation, is usefuleither when 'the receptacle member is mounted on a fixed support asshown, or when the plug and receptacle members are used to constitute aline connector, without any support.

' Referring now to Fig. 4, it will be seen that a block of insulatingmaterial 15 is housed within the casing of the receptacle member I andthat mounted in pockets or recesses in this block are a plurality ofcontact elements It, each in the nature of a U-shaped clip having a pairof parallel arms. By reference to Fig. 6 it will be seen that two suchclips l6 are provided and that there is also another and smaller similarclip 18 mounted in the receptacle member. A stem or shank I1, passingthrough the insulating bushing connects each clip IS with a conductorl9, these conductors constituting the main power leads. A similar stemor shank I1 connects the clip H! to another conductor 20 whichconstitutes the usual ground wire commonly employed in the safetysystems used in mines.

Housed within the casing of the plug member 2 "is a block of insulation2| and mounted in the recesses in the face of this block adjacent thereceptacle member are a pair of contact elements 22 in the nature ofblades, and a similar and smaller contact element or blade 23. It willnow be apparent from an inspection of Fig. 6 that when the members ofthe connector are brought together in closed or assembled relation, theblades 22 enter theclips [6 while the blade 23 enters the clip 18, thusestablishing the desired connections.

Each blade 22 is connected by a stem or shank 24 with a binding post 25,and the blade 23 is connected by a similar stem or shank 24 with abinding post 25', these binding posts being mounted in recesses in theouter face of the block 2| as clearly shown in Figs. 4 and 5.

Secured to the binding post 25 are a pair of main conductors or powerleads 26, while secured to the binding post 25 is another conductor 21constituting the ground wire.

The three conductors 28 and 21 are formed into a flexible cable 28 ofthe usual construction. The ground wire 21 may be a circular conductorbut is shown in Fig. 2 as consisting of a flat strip embedded, in' theinsulation between the two main conductors 26, the assembly thus forminga cable of oval cross-section. This cable is tightly held by a clampingdevice comprising a body portion 29, recessed to receive the cable, anda yoke 30 shaped to enter the recess and bear against the cable. Thisyoke is forced toward the body of the clamp by means of a pair of bolts3|, thus securely gripping the cable between these parts.'- The body' 29of the clamp is rigidly secured to the outer end of the pyramidalportion of the plug member as by welding, as indicated at 32. By thusclamping the cable to thecasin'g' of the plug member the leads 26 and 21and binding posts 25 are relieved of any mechanical strain.

One form of improved circuit closer or controller which I may employ forcarrying out the purposes of the invention is illustrated in Figs. 1. 3,4 and 7 and comprises a'mercury tubes'witch 33 supported on a block34mounted on a shaft 35 journalled for rocking movement in'a" bracket 36projecting from the end wall ofthe receptacle member I. "A lever 31 isalso secured to this shaft 35 and is formed'with a tail piece 31'against which bears one end of a compression spring 38. the other end ofwhich bears against the receptacle member 1. Thus this spring 33 tendsto rock the lever 31 and the tube 33 from the full line to thedotted"lineposition shown in Figs. 1 and- 4. It will be understood thatwhenthe mercury tube-switch is in the position shown in full lines inall of the figures the circuit-controlled thereby is open; whereas, whenthe "switch is tilted to the dotted line position shown in Figs. 1 and4, the mercury flows back to the rear end and bridges contacts to which,wires 39 are con-'- nected, thus. closing the circuit through thesewires. v, j";.

Referring again more particularlyto Figi4' it will be seen that Iprovide a push rod 40 having its outer end bearing against the lever 31.This rod is slidably mounted in a suitable bushing 4| and guide tube 42extending through the insu'la tion l5, such rod having a collar 43secured thereto and being surrounded by a spring 44 which bears againstthis collar and tends tourge the rod inwardly. The inner end of the rodpasses through a suitable bushing 45 and terminates in a pocket orrecess in the face of the insulation l5 adjacent the plug member. 7 Setinto the adjacent face of the block of insuf lation 2| in the plugmember is an abutment in the nature of a stud or button 46, sopositioned as to bear against the inner end of the ush rod 40 when theplug and receptacle 'menibers are in the closed or assembled positionshown in full lines in'Figs. 1 and 4.- When in such position, the stud,acting through the push rod 40 and lever 3 serves to maintainl. themercury itube switch Ji in i its mill hne or open-zpositioni Instead ofoperating -the niercury tube' ::switch 33 by-means f the spriri'g 38shown in F igs; 11. and 4, I---ma-y operate it direotly my" the movementof the rod 40 as illustrated in Figs.-1-2 to 1 4 inclusive. Referring tothese ngures-. it-wi11 be seen that I employ a rocking =l'ever- 3'|-'having a biiurcatedupperend which embraces a spool or fitting St-securedto the rod lfl sas bymeans-"of as'et screw 85. Thero'd 40 is actuated bythe seine-spring 44 as-shown in Fig. 4','-and whenithis rod isreciprocated it cperates through the leven 31 F to mock or tilt themercury tube switch. I

Referring '=now to Fig. 15, iI-ha ve illustrated conventionallya 'threepole circuit-breaker cornprising an -.oper ating:rod 4 1 carryingthreesswitoh:

members :41 adapted to engage f pairs of -conta'cts 4-1 one co'ntaet oftwo these pairs as con nected to a source of current while the 'other"contact or these ipairs is connected -:with the main power leads lS.'Fhe "otherpair or c'ontact's 41 -serves -to contr'ol the lgroulid' wirezll.

The switch members M are-normally main tained -in engagement with thecontacts ll,

against the tension of lithe spring 52 by means of a detent--48,on therod H ,engaging a latch mem-- ber 50; I This latch "member 50 isp'ivo'tally *connccted -at 5U to-one end of a sliding '56,

51' with the-upperenu or a rod 5 I. which rod carries a collar againstwhich bears ia-compression spring 53 which tends to maintain the rod andlatch 50 m their uppermost position as shown iniull lines.

-As is usual, -the oircuit breaker is providedwith overload trip *coils54 connected in -one-or both o'f the power leads 19-, endwith a gr'oundlimiter coil 55 connected with-the ground wire-10. For the purposes ofsimplicity and learness a'll-of' these coilsare shown'as-surroundingcores-eo1r' rent flows in any of these coils the latchmember 'ill-i-sirfirajoted "to its lowermost'iposition, shown indottedlines, thus disengaging thelatcnfrom the detent 48; "This trips thebreaker and allows it to be automatically opened *by the spring 52,as-indicated bydotted lineirrFig.15.

When it :is desiredto reset the breaker after it has been tripped, theoperator pulls back the lever '49. The upward pressure of thespringalong on the detent 48 until the latch-has'moved farenou'gh-so that'its=end -sl1ps=dfi 'o'f an'd engages behind the detent ee -illustratedin-dotted lines in .Fig. 16. Thereupon by "swinging tlie 'lever 49toward full line pcsition, the-rod ll may be pusheii: back toward theleft -50 as "to restore the breaker the :other end'xof whichconnecteiisbyrwire in: with the other power lead. Atcutoffswitehmriayoperated by :the rod :41, is interposed in the con- Thiscut-oh. switch automatically opens when the breaker opens :andclosesiwhen the Fbreaker is-c-losed. "In other words, it :opens.

ductor 51.

and closes with the breaker.

It will he soon that "wheni th'e :parts :are :in the position shown in:full lines in .:F.ig. :15, the circuit 1' through the fshunt itrip :coil5 6.:is comp1ete;except at I the mercury tube switch 3-3. 1f therefore,un-

der these conditions, this :switch is tilted to dot ted line position,it will close the@ circuit through the shunt trip coil, thus energizingthe same and tripping the breaker, allowing it .toopern,

I-o repeah -when the parts of theiconr iectl'ir are iniasse'mbled orclosed position as shown -in: fiill:- lines in -Figs. 1 and 4, thennercury'tubesswitchv 33 is also in the position showniin itull lines; iand in this-position the circuit through wires 3'9 open. 'Letit beassumed thatiit is desired toopen or disconnect the connector. The:operator :releases the latch II and then swingsithezouterentl of theplug member upwardly about the :pivotsi l fl.

The initial movement-of the plugmem-ber iron:

closed. position however, serves :to:shift"the abut-:-

ment stud-46 out of contact-with theinner en'd of push rod 40, thuspermitting this rod :to move: inwardly. Thereupon, by the mechanismshown either in Figsgl and 4 01 Figsal2, 13 and 14, the tube 33 isrocked into the dotted line position.

coil 56.

the main leads I9 from the-sourcezdf current.

the same time the switch 58 'opens,;thusbreakingu the circuitthrough theshunt tripcoil.

Itwill be noted that thisitiltingofithe mercury tube switch 33 and theclosing of the circuit through the wires 38 takes place when theiplug.

member has been swung no further than indicatedin dotted'lines in Fig.1, that is'to say while the clips 1-6 and blades'22 ofthe maincontactelew ments are still in full engagement. Thereafter,

when theplug is swung around intothe position. shown indotted'lines inFig; 4,.so asto disengage.

theconta'ct elements [6 and 22,these elements; at the time of theirfinal separation iare corm pletely dead or cold, and therefore*alliaarcingmr sparking at such contacts is eliminated. Imother words,the initial movement of theiplug memberr serves to disconnect thecontact-elements ofrthe: receptacle member from the source-of :currentcompletely, before the contact elements of thetwo members aredisengaged.

Should the operator attempt to -T+C1OS the breaker, by means of thelever 49, before the plug and receptacle members or the ="connectorihave been again brought completelyinto' closed 'OI'Z'BJS" semhledrelation, and thus befo're 'theiistud whas. moved the switch 33 to fullline or iopenipos'ition, the cut-off switch 58, whichiis preferably.-seti to close slightly in advancetoffthe breakernontacts, will closefirst. The mercury tube switch being already-closed, theshunt tripicoilflwill be imme diately energized and vthe latch 50 tripped out of.engagement with the rod -41, .soxithat'l the: breaker is prevented fromreaching CIOSHdSIJOSitiO'n. other words, it is :impossible to .close.the hrs-alter; if 'the plug and receptacle memberstof the-connec-v torhave not been "broughtzinto:completely assembled relation.

While by way of illustration I have shown in: Fig.;1 5:theoverloadrcoils; ground? limitermoil and' shunt trip coil as alloperating directly on the ping mechanism, such as an arrangement includ3. ing. relays, can be employed without departing from the spirit of theinvention.

:. There are many other ways in which the initial swinging movementof.the plug member can be made.,..to close the circuit through the shunttrip coil,'inste,ad of employing a mercury tube switch, such as abovedescribed. One of these alternative ways is shown in Fig. 8. In thisfigure I have illustrated the circuit through wires 39 asbeingcontrolled by a push-butt0n type switch 60 having, anzoperatingheador button 59 against which the end.;of .1push rod-10 engages. The switch60 may be supported on .the receptacle member I by means of a suitablebracket 6 i. It will be understood that the push-button switch 60 is thetype which remains open as long as pressure is applied to the head 59,but which closes automatically when this pressure is removed.

It will be observed that in both of the arrangements shown in Figs. 1and 4 and in Fig. 8 the circuit closing switch is located wholly outsidethe plug and receptacle members constituting theconnector. Thus it isnot necessary to bring the control wires 39 inside of the connector.

:In Figs. 9, 10 and 11 I have illustrated still another form of circuitclosing device which may be employed. In this form, instead of thepush-rod and associated parts illustrated in Fig. 4, I employ a. pair ofresilient contacts 62 mounted in a recess or: pocket in the block of ins:Llation l5, and the control wires 39 are brought into the connectorthrough a suitable bushing and fastened to these contacts 62. Thesecontacts are so constructed that they normally tend to engage each otheras shown in Fig. 11, thus closing the circuit between thewires 39.Normally however, when the connector is in fully closed or assembledposition as shown in Fig. 2, a wedge block 63, of insulating material,set into the plug member, enters between the contacts 62. and holds themapart, as shownpin Fig. 10, thus maintaining the circuit be tween thewires 39 open. During the initial upward swinging movement of the plugmember 2, however, this wedge block 63 is withdrawn from between thecontacts 62, thus permitting them to come into engagement, and to closethe circuit through the wires 39, thereby tripping the breaker as abovedescribed. I

..Fig. 11 alsowell illustrates how the breaker is tripped during theearly stages of the movement of the plug member, and while the contactele-' ments l6 and 22 are still in substantial engagement. I

Still other means by which the initial movement of the plug member aboutits pivot can be caused to energize the shunt trip coil and thus tripthe breaker will readily suggest themselves to'those skilled in the art.

.Referring again to Fig. 4, in conjunction with Figs. 10 and 11, it willbe seen that the means for closing the control circuit through wires 39are located at a much greater distance from the pivot l0 than are themain contact elements it and 22. Thus in the case of Fig. 4, the stud46, and in the case of Figs. 10 and 11, the wedge block 63, moves muchfarther and faster than does the contact blade 22. Hence the controlmechanism operates before the blade moves to any substantial extent. g

-'-'By.-v1rtue ofthe elongatedform or the plug memberjgand its, pivotalconnection with the; receptacle member asshowm an efiective lever;action is provided, and this gives the operator a mechanicaladvantagewhich greatly facilitates. 5 moving the contact elements intoand out of engagement. WhatIclaimis: .l 1. ,In a power distributionsystem, the combination with a connector comprising separable'rejceptacle and plug members having interengaging; contact elements, of acircuit breaker controllingi the supply of current to said connector,ashums trip for causing said circuit breaker to 09 .1 means responsiveto the initial relative separating movementof said plug and receptaclemembers for operating said shunt trip, manual means-for: reclosing saidbreaker, and means for preventing; re-closing of said breaker untilaiter saidcontactl elements have been again brought intovfull en-i.

e sement- .r 2. In a power distribution system, the combination with aconnector comprising separablere-- ceptacle and plug members havinginterengaging overlapping contact elements, and conductors connectedwith the contact elements of each, of, a circuit breaker controlling thesupply of current: to said connector, a circuit closer independent of;said conductors located wholly outside of said plug and receptaclemembers, means whereby the actuation of said circuit closer trips saidbreaker, and means operated by the initial relative move mentor saidplug and receptacle members for actuating said circuit closer beforesaid contact elements are disengaged. 3. In a power distribution system,the combine tion with a connector comprisingseparable re ceptacle andplug members having inter-engaging: contact elements, of conductorsconnected with the contact elements ofboth said receptacle and; plugmembers, a circuit closer independent of said; conductors, separate fromand located wholly, outside of said plug and receptacle members,andmeans operated by the initial movement of said plug member in separatingit from said receptacle member for automatically actuating said circuitl r-Y.

4. The combination with a connector comprise: ing separable receptacleand plug members hav; ing interengaging contact elements, of conduc torsconnected with the contact elements of both; said receptacle and plugmembers, a push rod; slidably mounted in said receptacle member, anabutment carried by said plug member for engaging and moving said rod,and a circuit c on trolling device independent of said conductors OP-ferated by said rod.

5. The combination with a connector compris ing separable receptacle andplug members having interengaging contact elements, of a pivotally amounted mercury tube switch, spring means for maintaining said switch inone positiorna push rod slidably mountedin said receptacle member,- anabutment carried by said plug member for en; gaging and moving said rod,and means operated by said rod for rocking said tube switch on its pivotagainst the tension of said spring into-another position.

6. The combination with a connector comprising separable receptacle andplug members hav ing interengaging contact elements, of conductorsconnected with the contact elements of both said receptacle and plugmembers, a push rod slidably mounted in said receptacle member, anvabutment carried by said plug member .for en- 15 sa nse nd; mo in aid9d-.1.e$. sale, P 98 is serted in said receptacle, and a circuitcontrolling device independent of said conductors in the nature of apush-button switch operated by said rod.

'7. In a power distribution system, the combination with a connectorcomprising separable receptacle and plug members having interengagingcontact elements, of a fixed support on which said receptacle member ismounted, means pivotally connecting said plug member to said receptaclemember adjacent one edge so that said members are separated by aswinging movement of said plug member about its pivot, a circuit closercarried by said receptacle member said closer being open when the saidcontact elements of the connecter are in normal fuel engagement, andmeans operated by the initial swinging movement of said plug member forautomatically causing said circuit closer to close.

8. In a power distribution system, the combination with a connectorcomprising separable receptacle and plug members having interengagingcontact elements, of a fixed support on which said receptacle member ismounted, .means pivotally connecting said plug member to said receptaclemember adjacent one edge so that said members are separated by aswinging movement of said plug member about its pivot, a circuit closercarried by said receptacle member said closer being open when the saidcontact elements of the connector are in normal fuel engagement, andmeans located at a greater distance from said pivot than said contactelements and actuated by the swinging movement of said plug member forautomatically causing said circuit closer to close.

9. In combination, a connector comprising separable plug and receptaclemembers having interengaging cont/act elements enclosed therein, saidplug member being of elongated form and pivotally mounted at one end onsaid receptacle member adjacent one edge thereof, and a flexible cableentering the opposite end of said plug member, and connected with thecontact elements therein, whereby said plug member may be swung aboutits pivot with a lever action in bringing said contact elements into andout of engagement.

10. In combination, a connector comprising separable plug and receptaclemembers having interengaging contact elements enclosed therein, saidplug member being of elongated form and pivotally mounted at one end onsaid receptacle member adjacent one edge thereof, a flexible cableentering the opposite end of said plug member, and connected with thecontact elements therein, whereby said plug member may be swung aboutits pivot with a lever action in bringing said contact elements into andout of engagement, and a spring catch at the opposite edge of saidreceptacle member for locking said members together in assembledrelation.

. DARWIN A. ENSIGN.

REFERENCES CITED The following references are of record in the file ofthis patent:

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